Iveco Euro Cargo 6 10t Repair Manual
Iveco Euro Cargo 6 10t Repair Manual
Iveco Euro Cargo 6 10t Repair Manual
EUROCARGO TECTOR
6 TO 10 t
REPAIR MANUAL
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”This document provides data, characteristics, instructions and
methodology to perform repair interventions on the vehicle
and its components.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified and equipped to perform
the repair interventions that are indicated in this document.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accident prevention devices, such as, as a rough guide, goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., are available and efficient, and further
make sure that the vehicle is put such a way that an
intervention can be made in safety conditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of
functionality, efficiency and safety conditions that are provided
by Iveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of any responsibility for Iveco,
and, in particular, where the vehicle is covered by a guarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Iveco is available to provide all clarifications necessary to make
interventions, as well as to provide indications in cases and
situations not included in this document.
Data and information contained in this document could result
not to be updated owing to modifications made by Iveco at
any moment for technical or commercial reasons, or because
of the need to adapt the vehicle to law requirements in
different countries.
In the case of a difference between what contained here and
what actually found on the vehicle, please contact Iveco
network before making any intervention.”
The data contained in this publication might fail to reflect the
latest changes which the Manufacturer may introduce at any
time, for technical or sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.
Produced by:
SYMBOLS — WARNINGS
General danger
! It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 °C
Sealant
Cold
Adhesive
Winter
Temperature > 0 °C
Air bleeding Hot
Summer
Replacement
Original spare parts
Product Code: 5 0 7 6
PRODUCT UNIT SUB—ASSEMBLY PRODUCT UNIT SUB—ASSEMBLY
COMPONENT COMPONENT
The first and second figures identify the PRODUCT within motor vehicle.
Example :
Unit Code: 0 1 0 3
PRODUCT UNIT SUB—ASSEMBLY PRODUCT UNIT SUB—ASSEMBLY
COMPONENT COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT.
Example :
Sub—assembly Code: 4 0 1 3
PRODUCT UNIT SUB—ASSEMBLY PRODUCT UNIT SUB—ASSEMBLY
COMPONENT COMPONENT
The fifth and sixth figures exactly identify the SUB—ASSEMBLY and Component of a Unit within a PRODUCT.
Example :
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general—purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co—operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph “Controls
care of user” of Use and Maintenance handbook.
In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanned
a vehicle in motion during repair interventions.
Keep the vehicle stationary by proper chocks.
In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special support
stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.
When it is necessary to perform an intervention on methane—fed vehicles, observe the indications contained inside the
document, as well as all specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 12—point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR — BAG systems, scrupulously observe
indications specified in relating manual sections.
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight—fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12—point cards for provisions to make.
Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detached
or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self—locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
1 Pay attention that jamming sources are not present in the cab or near the keys.
2. Keys not insered in the panel must be at least 1 meter away.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.
— Electronic central units must be connected to system bonding when they are provided with a metallic shell.
— Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
— Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
— Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
— If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
— Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
Figure 2
88039
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 Hp = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
(Nm and bar units are converted according to 10:1 and 1:1 for the sake of simplicity)
1 kgm = 10 Nm
1 kg/cm2 = 1 bar
Temperature
0° C = 32° F
1° C = (1 x 1.8 + 32) ° F
UPDATE DATA
Section
General Specifications 1
Engine 2
Clutch 3
Gearbox 4
Propeller shafts 5
Rear axles 6
Axles 7
Suspensions 8
Steering system 10
Scheduled maintenance 13
Electric system 14
SECTION 1
General Specifications
Page
FILLING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MODELS
ML60E13R/P
ML60E15R/P
ML65E13R/P
ML65E15R/P
ML60E13KR
ML60E15KR
ML65E13KR
ML65E15KR
ML60E13/P
ML60E15/P
ML65E13/P
ML65E15/P
ML60E13R
ML60E15R
ML65E13R
ML65E15R
ML60E13K
ML60E15K
ML65E13K
ML65E15K
ML60E13
ML60E15
ML65E13
ML65E15
UNITS
F4AE0481D (130HP) • • • • • • • • • • • •
F4AE0481C (150HP) • • • • • • • • • • • •
F4AE0481A (170HP)
F4AE0681E (180HP)
F4AE0681D (210HP)
13” • • • • • • • • • • • • • • • • • • • • • • • •
2855S.6 • • • • • • • • • • • • • • • • • • • • • • • •
2865S.6
2870S.9
5833
5833/1 • • • • • • • • • • • • • • • • • • • • • • • •
4517 • • • • • • • • • • • • • • • • • • • • • • • •
4521
TRW-TAS 30 • • • • • • • • • • • • • • • • • • • • • • • •
ZF 8090
Front mechanical • • • • • • • • • • • • • • • • • • • • • • • •
Rear mechanical • • • • • • • • • • • • • • • •
Front pneumatic
Rear pneumatic • • • • • • • •
MODELS
ML75E13R/P
ML75E15R/P
ML75E17R/P
ML75E18R/P
ML75E13KR
ML75E15KR
ML75E17KR
ML75E18KR
ML75E13/P
ML75E15/P
ML75E17/P
ML65E18/P
ML75E13R
ML75E15R
ML75E17R
ML75E18R
ML75E13K
ML75E15K
ML75E17K
ML75E18K
ML75E13
ML75E15
ML75E17
ML75E18
UNITS
F4AE0481D (130HP) • • • • • •
F4AE0481C (150HP) • • • • • •
F4AE0481A (170HP) • • • • • •
F4AE0681E (180HP) • • • • • •
F4AE0681D (210HP)
13” • • • • • • • • • • • • • • • • • •
14”
2855S.5 • • • • • • • • • • • •
2855S.6 • • • • • • • • • • • • • • • • • • • • • • • •
2865S.6
2870S.9
5833
5833/1 • • • • • • • • • • • • • • • • • • • • • • • •
4517 • • • • • • • • • • • • • • • • • • • • • • • •
4521
TRW-TAS 30 • • • • • • • • • • • • • • • • • • • • • • • •
ZF 8090
Front mechanical • • • • • • • • • • • • • • • • • • • • • • • •
Rear mechanical • • • • • • • • • • • • • • • •
Front pneumatic
Rear pneumatic • • • • • • • •
MODELS
ML80E17DR/P
ML80E17DKR
ML80EL15R/P
ML80EL17R/P
ML80E17R/FP
ML80E17D/P
ML80E17R/P
ML80E17DR
ML80E17DK
ML80EL15/P
ML80EL17/P
ML80E17/FP
ML80E17KR
ML80EL15R
ML80EL17R
ML80E17/P
ML80E18/P
ML80E17D
ML80E17R
ML80E17K
ML80EL15
ML80EL17
ML80E17
ML80E18
UNITS
F4AE0481D (130HP)
F4AE0481C (150HP) • • • •
F4AE0481A (170HP) • • • • • • • • • • • • • • • • • •
F4AE0681E (180HP) • •
F4AE0681D (210HP)
13” • • • • • • • • • • • • • • • • • • • • • •
14” • •
2855S.5 • • • •
2855S.6 • • • • • • • • • • • • • • • • • • • • • • • •
2865S.6
2870S.9 • • • • • • • • • • • • • • • •
5833 • • • • • • • • • • • • • • • •
5833/1 • • • • • • • •
4517 • • • • • • • •
4521 • • • • • • • • • • • • • • • •
TRW-TAS 30 • • • • • • • • • • • • • • • • • • • • • • • •
ZF 8090
Front mechanical • • • • • • • • • • • • • • • • • • • • • •
Rear mechanical • • • • • • • • • • • • •
Front pneumatic • •
Rear pneumatic • • • • • • • • • • •
MODELS
ML80E18DR/P
ML80E21DR/P
ML80E18DKR
ML80E18R/FP
ML80E21R/FP
ML80E18D/P
ML80E21D/P
ML80E18R/P
ML80E21R/P
ML80E18DR
ML80E21DR
ML80E18DK
ML80E21DK
ML80E18/FP
ML80E21/FP
ML80E18KR
ML80E21/P
ML80E18D
ML80E21D
ML80E18R
ML80E21R
ML80E18K
ML80E21K
ML80E21
UNITS
F4AE0481D (130HP)
F4AE0481C (150HP)
F4AE0481A (170HP)
F4AE0681E (180HP) • • • • • • • • • • • •
F4AE0681D (210HP) • • • • • • • • • • • •
13”
Single plate 13”/14” • • • • • • • • • • • •
14” • • • • • • • • • • • • • • • • • • • • • • • •
2855S.5
2855S.6 • • • • • • • • • • • •
2865S.6 • • • • • • • • • • • •
2870S.9 • • • • • • • • • • • • • • • • • • • • • • • •
5833 • • • • • • • • • • • • • • • • • • • • • • • •
5833/1
4517
4521 • • • • • • • • • • • • • • • • • • • • • • • •
TRW-TAS 30 • • • • • • • • • • • •
ZF 8090 • • • • • • • • • • • •
Front mechanical • • • • • • • • • • • • • • • • • • • • •
Rear mechanical • • • • • • • • • • • • •
Front pneumatic • • • •
Rear pneumatic • • • • • • • • • • •
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